Increasing Reliability of Motors by Absorbing High ... · in the case of maintenance and avalability. Other Applications:EMC Filters, Common Mode Chokes, Transformers, Automotive

© MAGNETEC GmbH, Germany Hans‐Joachim Poess 1Increasing Reliability of Motors by Absorbing High frequency Noise with inductive Absorbers

MAGNETECMAGNET-TECHNOLOGIE

Presentation from Hans-Joachim Poess 2015 Motor & Drive Systems 2015

Manager EMC and Head of Development at www.magnetec.de

Variable Frequency Drives are driving Motors and control the applications. The high performance of the VFD helps to save Energy and save costs. To have a reliable application it is needed to careAbout the high frequency Common Mode Noise which can damage the Motors, Bearings, Sensors and other components. To eliminate this HF Common Mode Noise the most efficient and maintenance freeSolution is to Absorb it and change it to safe thermal energy. How to do this will be

described in the Presentation.

V 1.0 20141211



Histrorical Grinding systemCurry Cinnamon, Kardamom, Marsala …

Without electroerosion of the bearings ;=)

Where we do not need Inductive Absorbers:



All kind of electrical drive and converter systemsWhere we do we need Inductive Absorbers:



Cool Blue Plus+

What are Cool Blue inductive Absorbers1Where they are used2What is the advantage3Which improvement4Outview (new Typeline)5Other new Products …6



1 What are Cool Blueinductive Absorbers

Nanocrystalline Ringcores made out of a ~ 20µm thickamorphous strip changed to nanocrystalline Structure by an annealing Process to a grain size of about 20 Nanometers.This gives about 1000 insulated areas only in the heightdirection of the tape.

The Power losses of Nanoperm is about 1000 times lowerthan from typical Silicon Iron.

The frequency range is fromsome Herz up to the 100 Mega Herz area.



melting furnace

inductionheating

liquid metal under pressure,T = 1200°C

ceramic nozzle

amorphous strip20-25 m thickness

Cu casting wheelT = 20°C

v = 100km/h

Laboratory fabricationAmorphous Tape



2 Where they are used

To avoidelectroerosionespecially in Motorbearings



2 Where they are usedTo avoid electroerosion in industrial applications ,especiallyin Motorbearings, Gearboxes, Sensors a.s.o.



3 What is the advantageEasy to mount and to retrofit

Low cost compared to other sollutions like Hybrid Bearings

Easy to select

Working parallel against conducted and radiated emissions

Maintenance free

Workingtime over decades (when correct designed)

Effect is immediate seen (Sum Peak Current)



Which improvement4



4 Improved Inductivity



Which improvement

0,00E+00

2,00E‐01

4,00E‐01

6,00E‐01

8,00E‐01

1,00E+00

1,20E+00

1,40E+00

10 100 1000 10000 100000

|Z|/Ω

Frequenz [kHz]

|Z|(Cool Blue +)(f)/|Z|(Cool Blue)

Up to over 20 %

20 % 100 MHzestimated

Measured values

4



Outview (new Typeline)5Possible mechanical Dimensions



NANOPERM®plate‐coresforwirelesspowertransmission

roundplate‐corePermeabilityµr~5kDimensionOD~300mmID~16mmH~9mm

rectangularplate‐corePermeabilityµr~30kDimensionofonebar:200x20x5

diamand‐core‐shapePermeabilityµr~30kDimensionofthebars:20‐100x10x5

Other new Products6



Cool Blue Cores are increasing the reliabilityof Motors and complete Machines in the case of maintenance and avalability.

Other Applications:EMC Filters, Common Mode Chokes, Transformers, Automotive EMC components against Radio disturbance, inductive Heating,

With the new Cool Blue Plus + the performance is over 20 % higher

Cool Blue Cores are absorbing the dangerous electrical noise andchange it to save thermical energy

No expensive insulated (Hybrid) Motorbearings are needed in many cases



Special Electro Erosion800kV Discharge



Adding NANOPERM Line Aborbers NaLA type M-381

option for effect demonstration :deactivate cores by a shortcut

2 x M-113



Reducing Ipeak from ~ 40 A down to ~ 6 A by combination ofCOOL BLUE Cores and NANOPERM Line Absorbers NaLA

and smoothening the High Frequency away

without cores

with combined cores



Solution: Combine the COOL BLUE Cores and NaLA coresto absorb the Common Mode Noise to save thermal Energy

2 x M-112 COOL BLUE Cores

6 x M-381 (NaLA)

UVW

L1L2L3

shield

Common Mode

Differential Mode



Solution: Combine the COOL BLUE Cores and NaLA coresto absorb the Common Mode Noise to save thermal Energy

2 x M-367 COOL BLUE Cores

3 x M-053 (NaLA)

UVW

L1L2L3

shield

Common Mode

Differential ModeN=2

7,5 KW 50 m



1. Common Mode Noise suppression for Inverter driveswith NANOPERM Cores

Table: selection and amount of Cool Blue Cores depending on rated power and cable length Hans‐Joachim Poess

All data are for information and not guaranteed values.

Inverter power range up to

Kilowatt 0,7 7,5 30 75 315 1.200 > 1.200

horse power 1 10 40 102 428 1.631 > 1.631

p/n oval n/a M‐049 M‐049 M‐283 M‐302 M‐111 M‐248

p/n round M‐923 M‐367 M‐367 M‐113 M‐116 M‐117 n /a

Cable length

[m]

50/164 ft 2 2 4 4 4 4 4

Amountofcores

[pcs.]

100/328 ft 4 4 4 4 4 4 4

150/492 ft 4 4 6 6 6 6 6

300/984 ft 4 4 6 6 6 6 6

Low power range (up to 10 kw) need some times 2 turns on the Nanoperm cores

N=1N=2



Table : selection and amount of NaLA Cores depending on rated power and cable length Hans‐Joachim Poess

All data are for information and not guaranteed values.

Inverter power range up to

Kilowatt 0,7 7,5 30 75 315 1.200 > 1.200

horse power 1 10 40 102 428 1631 > 1.200

p/n M‐606 M‐053 M‐102 M‐381 M‐613 M‐614 M‐616

core sizeDa Di h [mm]

16x11x5 25x20x10 30x20x10 40x32x15 80x63x30 100x80x30 160x130x30

Cable length

[m]

50/164 ft 2 1 1 1 1 1 1

Amountofcores

[pcs.]

100/328 ft 4 2 2 2 2 2 2

150/492 ft 6 3 3 3 3 3 3

300/984 ft 8 4 4 4 4 4 4

2. Differential Mode Noise suppression for Inverter driveswith NANOPERM Line Absorbers NaLA

If the NaLA cores getting too warm, use the double amount each line



MR – Typelines (µr > 8000)Cool Blue Cores for Power Applications

Mechanical shape like the R-series from Power Ferrites

Higher Inductivity

Higher Impedance

Higher Saturation Induction

Higher using Temperature

More Robust

1:1 Substitution to Power Ferrites but better Performance.

No change of Capacitors needed



Ln-Inductivity at 100 kHz; Isat – Saturation current DC, all values are for information only. Details are in the dataheets.

Our Ring cores are based on Nanocrystalline soft magnetic tape material NANOPERM. Compared to ferrite cores, the following advantages on the same core size are achieved: higher Inductivity higher Saturation current optimised Power losses mechanicaly extremely robust higher continuous component temp (120°C) higher Frequency bandwidth from Hz up to 100 MHz

Cores are available for the nominal current range from 1 – 1000 Amps and higher, designed acc. to EN60938-1 for UN = 500V. Operating temperature range: -40...+120°C. The casing material is UL listed and fulfils UL-94 V0.

Types (Extract)

dout x dinner x height [mm]

LN @ 100kHz

[µH]

Isat [A]

MR-055 55x32x18 11 13 MR-063 63x38x25 14 15 MR-080 80x40x15 11 18 MR-102 102x66x15 8 25 MR-140 140x103x25 8 38 MR-202 202x153x25 8 55

Even bigger available

MR – Typelines (µr > 8000)Cool Blue Cores for Power Applications



How to measure

Common Mode Noise and

how to absorb it withCool Blue Cores (Inductive Absorbers)



Inverter with a standard motor and a DC-load-motor



Measuring Voltages and Common Mode Currents



What is the source of the Problem: Common Mode Currents in high frequencies



High frequencies in the MHz range



Why Mhz and not kHz ?

Because of the impedance of the Motor, especially the bearings:



Where does this currents come from ?

IGBT is the source of theNoise and the current loops back



Where are the vagabonding currents running ?

Runs over groundingpathes like brushes



How can we avoid these vagabonding currents ?

Absorb the currents

And change it

Into

Thermal energy

By using

Inductive Absorbers

Cool Blue



What is the effect of the Inductive Absorbers ?

Without inductive Absorbers With inductive Absorbers



How to check ?

Shortcut open the loop



How is the Common Mode Current changing with theamount of Cool Blue Cores ?



What happens on more turns ?

It helps !

The Cool Blue Cores should not go into saturationThe parasitic capacity should be low enough



Theoretical Background: SimulationVoltage



Theoretical Background: Simulation no Saturation

Voltage

Current

Current



Theoretical Background: Simulation with SaturationVoltage

Current

Current



To avoid saturation:

New material parameters ofNanoperm

Low mySaturation current up to

Factor 80



Diagram L(f) low my 1000 - 8000

0

0,000002

0,000004

0,000006

0,000008

0,00001

10 100 1000 10000

L [H

]

frequency [kHz]

Nanoperm low my 63x50x30 different permeabilities

µ 1000

µ 2000

µ 4000

µ 8000



Low my diagramm L(I)

0,00

1,00

2,00

3,00

4,00

5,00

6,00

7,00

10 30 50 70 90 110 130 150 170 190

indu

ctiv

ity (µ

H)

current (A)

Nanoperm low my 63x50x30 different permeabilities

Inductivity ( current) turn no =1

µ8000

µ4000

µ2000

µ1000



Calculation Imax Nanoperm of µr

H= I*N/lfe magnetic field (A/m)

B=µ0*µr*Imax*N/lfe magnetic induction (Vs/Am)

B=µ0*µr*H

Imax= (B*lfe)/(µ0*µr*N)

B= 1 Vs/Am material constant Nanoperm (1,2T) 20 % savetymargin

µ0= 4*pi*10^‐7 Vs/m² constant

µr – relative Permeability; N=turn no.Lfe – middle pathlength)



Dimensioning Imax calculation

Imax= (B*lfe)/(µ0*µr*N)

Examples on one core dimension

63x50x30 mmImax (µr=30000) = 4,8 AImax (µr=1000) = 143AImax (µr=500) = 286 A



Imax (dimensions and µ)

H= I*N/lfe B=µ0*µr*Imax*N/lfeB=µ0*µr*H Imax= (B*lfe)/(µ0*µr*N)B 1Vs/Amµ0 4*pi*10^‐7 Vs/m²

lfe (m) 0,18 0,225 0,28 0,36 0,45 0,58 1,49coredim 63x50x30 80x63x30 100x80x30 130x100x30 160x130x30 200x175x30 500x450x30µr Imax Imax Imax Imax Imax Imax Imax

100 1432,4 1790,5 2228,2 2864,8 3581,0 4615,5 11857,0500 286,5 358,1 445,6 573,0 716,2 923,1 2371,4

1000 143,2 179,0 222,8 286,5 358,1 461,5 1185,72000 71,6 89,5 111,4 143,2 179,0 230,8 592,94000 35,8 44,8 55,7 71,6 89,5 115,4 296,48000 17,9 22,4 27,9 35,8 44,8 57,7 148,2

30000 4,8 6,0 7,4 9,5 11,9 15,4 39,560000 2,4 3,0 3,7 4,8 6,0 7,7 19,880000 1,8 2,2 2,8 3,6 4,5 5,8 14,8

You can online calculate: http://www.magnetec.de/dimensioning/abacus/abacus.php



Different succesful applications

Wind turbines

Solar converter

And other Industrial Inverter – Applications

From Water pumps (some hundred Watt) up to

Stone grinding (Inverter steered up to 5 MW)

Power Distribution via GIS (Gas Insulates Switches in th 800 kV range)

Chillers



How did it start? proof‐of‐principle experiment in 2006

without filter cores ICM = up to 60A

with Cool Blue cores ICM ~ 10A –ok!

EMC measurements were carried out in the nacelle (height 80m)

Basic working Principle of Cool Blue



Professional airconditioners, ‘chillers’ up to 500kW

contains:M‐116M‐117Realisation: now

Professional airconditioning systems used in industrialenvironment, airports, office buildings etc. Function: EMC compliance, motor bearing protection

Cool Blue – application examples



typical configuration of Cool Blue cores in Photo Voltaic central inverter with P = 500kWFunction: EMC filter

Realisation: now

S500kW Solar Central Inverter for Power Plants




Photovoltaic Inverters Application Example

Photovoltaic : residential string Inverters: 3‐12 kW

our EMC chokes may partly replace Ferrit chokes



On the cables



Picture of cores with thermocouple

Thermocouples for checking overtemperature



eMobility: electrical Cars and Infrastructure

EMC products for on‐board and off‐board systems

On‐Board:

DC/DC converters for battery chargers and power supply in a range from 3,0 … 6 kW

DC/AC converters for motor drive in the range from 50 … 100 kW

electrical steering systems

Off‐Board:

Stationary Charging Stations 5 ‐25kW private and public

Option: ‘Witricity’



high voltage gas‐insulated switchgear, ‘GIS’

Cool Blue cores in a 800kV switchgear for a modern energy distribution system over long ranges

Function: absorption of destructive high current transient pulses




100 Ohm

140 Ohm

The Problem of the motor bearings are the resonances in the area of 100 kHz and in the area of some MHz.The low impedance drives high common mode currents up to 100 A through the motor and over the motor bearings.The living time of the bearings is dramatically reduced if the common mode current is working in this frequency range.To avoid this fast damaging, the impedance against common mode currents have to be increased.The working solution for this is a Cool Blue core which is made from Nano crystalline material (Nanoperm) which is put over the motor cables. This Cool Blue Cores have a high impedanceFor example: M-160 (160x130x30 mm³) µ~30000L~ 20 µH at 100 kHz (per turn)Z=2*pi*f*LZ~ 2*3,14*100000 Hz* 0,00002 H ~12 Ohms For each coreTypical numbers for the amount of the Cool Blue Cores are 4 – 8 Pc8*12 Ohm ~ 100 Ohms for 100 kHzFor 3 MHzZ~ 2*3,14*300000 Hz* 0,000001 H ~18 Ohms 8*18 Ohms ~ 140 Ohms for 3 MHzThis impedances are added to the common mode path and can reduceSignificant the common mode current down to the 10th part.This will increase the living time of the motor bearings up to factors.

This diagram shows the impedance of a Motor against Common mode noise



Magnetec in Hungary … and now … Thank you for your time !

Documents

Increasing Reliability of Motors by Absorbing High ... · in the case of maintenance and avalability. Other Applications:EMC Filters, Common Mode Chokes, Transformers, Automotive